Table of Contents
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Table of Contents
Troubleshooting
Related Manuals for Yamaha R6 2015 Series
Summarization of Contents
How to Use This Manual
Understanding Manual Structure and Symbols
Explains section titles, exploded diagrams, job charts, symbols, and how to interpret instructions.
General Information
Identification and Model Label
Details vehicle identification number location and model label affixed to the frame for spare parts.
Features: YCC-T/YCC-I System
Explains the mechanism, characteristics, and advantages of the Yamaha Chip Controlled Throttle and Intake systems.
Instrument Functions: Multi-function Meter Unit
Details the functions of the multi-function meter unit, including speedometer, tachometer, odometer, tripmeters, and clock.
Important Information for Service
Covers preparation for removal, replacement parts, gaskets, seals, O-rings, and fasteners.
Basic Service Information: Quick Fasteners and Electrical Handling
Details the removal and installation of quick fasteners and basic electrical parts handling.
Special Tools for Service
Lists specific tools, part numbers, and their reference pages for tune-up and assembly tasks.
Specifications
General Specifications
Provides overall dimensions, weight, and loading capacity of the vehicle.
Engine Specifications
Details engine performance metrics, including displacement, bore, stroke, compression, and fuel/oil specifications.
Chassis Specifications
Covers frame type, wheel specifications, tire information, and brake system details.
Electrical Specifications
Lists electrical system parameters such as voltage, ignition system, charging system, and battery specifications.
General Tightening Torque Specifications
Specifies tightening torques for standard fasteners with ISO thread pitch, applicable to various bolt and nut sizes.
Engine Tightening Torques
Lists specific tightening torques for engine components like camshaft caps, cylinder head, spark plugs, and oil pan bolts.
Chassis Tightening Torques
Provides tightening torque specifications for chassis components, including mounting bolts, brake caliper bolts, and steering stem nut.
Lubrication Points and Lubricant Types: Engine
Details lubrication points for engine components and recommended lubricants for various parts.
Lubrication Points and Lubricant Types: Chassis
Identifies lubrication points for chassis components like steering bearings and suspension parts.
Lubrication System Charts and Diagrams: Engine Oil Lubrication Chart
Illustrates the engine oil flow and identifies key lubrication points with numerical references.
Lubrication System Charts and Diagrams: Lubrication Diagrams
Provides diagrams showing oil flow through engine components like the cylinder head and crankshaft.
Cooling System Diagrams: Radiator Components
Illustrates radiator components including hoses, pipes, and the radiator itself.
Cooling System Diagrams: Cooling System Flow
Diagrams the flow of coolant through the engine, water pump, oil cooler, and radiator.
Cable Routing: Handlebar (front view)
Illustrates cable routing around the handlebar area, showing component connections and fastening points.
Cable Routing: Engine (right side view)
Details cable routing for engine components on the right side, including harness connections and clamps.
Cable Routing: Engine (left side view)
Shows cable routing for engine components on the left side, including harness management and coupler placement.
Cable Routing: Frame (top view)
Illustrates cable routing relative to the frame, indicating securement points and placement of harnesses.
Cable Routing: Headlight (left side and rear view)
Depicts cable routing for the headlight assembly, including sub-wire harness and relay connections.
Cable Routing: Rear fender (top view)
Shows cable routing associated with the rear fender, including battery, ECU, and light connections.
Cable Routing: Fuel tank (except for California) (left side and bottom view)
Illustrates fuel hose and harness routing for the fuel tank, excluding California models.
Cable Routing: Fuel tank (for California) (left side and bottom view)
Details fuel hose and canister routing specific to California models.
Periodic Checks and Adjustments
Periodic Maintenance Overview
Provides a general overview and chart for recommended periodic maintenance intervals and tasks.
General Maintenance and Lubrication Chart
Lists general maintenance items, their routines, and intervals for checks and lubrication.
Fuel Line Checks
Details procedures for checking fuel, vacuum, and breather hoses for damage and connections.
Spark Plug Checks
Explains how to remove, check condition, clean, gap, and install spark plugs for proper engine performance.
Valve Clearance Adjustment
Provides a step-by-step guide for measuring and adjusting valve clearance on a cold engine.
Crankcase Breather Hose Check
Details how to check the crankcase breather hose for cracks, damage, or loose connections.
Throttle Body Synchronization
Explains the procedure for synchronizing throttle bodies using vacuum gauges and a tachometer.
Exhaust System Check
Covers inspection of the exhaust pipe assembly and gaskets for leaks and proper tightening.
Canister Check (California Only)
Details the procedure for checking the canister and related hoses for damage or leaks.
Air Induction System Check
Refers to a specific page for checking the air induction system components.
Air Filter Element Replacement
Provides instructions for removing and installing the air filter element, emphasizing proper handling.
Clutch Lever Free Play Adjustment
Explains how to check and adjust the clutch lever free play using handlebar and engine side adjusters.
Brake Operation Check
Guides on checking front and rear brake operation for proper performance.
Brake Fluid Level Check
Details how to check brake fluid levels in front and rear systems, including precautions for refilling.
Front Disc Brake Adjustment
Explains how to adjust the front brake lever position for optimal reach and feel.
Front Brake Pad Check
Provides instructions for checking front brake pad wear and when to replace them.
Rear Disc Brake Adjustment
Guides on adjusting the rear brake pedal position for optimal engagement.
Rear Brake Pad Check
Explains how to check rear brake pad wear and when to replace them.
Front Brake Hose Check
Details inspection of front brake hoses and holders for cracks, damage, and fluid leakage.
Rear Brake Hose Check
Details inspection of rear brake hoses and holders for cracks, damage, and loose connections.
Hydraulic Brake System Bleeding
Provides a step-by-step procedure for bleeding air from the hydraulic brake system.
Wheel Checks
Covers inspection of wheels for damage, runout, and proper balance after replacement.
Tire Checks
Details inspection of tires for pressure, tread depth, damage, wear, and proper mounting.
Wheel Bearing Check
Explains how to check wheel bearings for smooth operation and excessive play.
Swingarm Operation Check
Covers checking swingarm operation for smoothness and excessive play.
Swingarm Pivot Lubrication
Details the lubrication of the swingarm pivot, bearings, spacer, and dust covers.
Drive Chain Slack Adjustment
Provides a procedure for checking and adjusting drive chain slack to maintain proper tension.
Drive Chain Lubrication
Offers guidance on cleaning and lubricating the drive chain, emphasizing O-ring care.
Steering Head Check and Adjustment
Covers checking the steering head for looseness or binding and adjusting it properly.
Lever Lubrication
Guides on lubricating the pivoting points of control levers for smooth operation.
Pedal Lubrication
Details lubrication for the pivoting points of control pedals.
Sidestand Check
Covers checking the sidestand for smooth operation and replacing if rough.
Sidestand Lubrication
Details lubrication for the sidestand's pivoting point and moving parts.
Sidestand Switch Check
Refers to another section for checking the sidestand switch operation.
Front Fork Check
Covers inspection of front fork legs for inner tube damage, oil seals, and general operation.
Front Fork Legs Adjustment
Provides detailed instructions for adjusting front fork spring preload and damping.
Rear Shock Absorber Assembly Check
Refers to another section for checking the rear shock absorber assembly.
Rear Shock Absorber Assembly Adjustment
Details how to adjust spring preload and rebound/compression damping on the rear shock absorber.
Connecting Arm and Relay Arm Check
Covers inspection of connecting arms and relay arm for damage or wear.
Engine Oil Level Check
Explains how to check engine oil level using the dipstick and identifies the oil level marks.
Engine Oil Change
Provides a step-by-step guide for draining and refilling engine oil, including oil filter replacement.
Engine Oil Pressure Measurement
Details the procedure for measuring engine oil pressure at specified RPM and temperature.
Coolant Level Check
Explains how to check coolant level in the radiator and reservoir, with precautions for handling coolant.
Cooling System Check
Covers inspection of cooling system components like hoses, pipes, water pump, and oil cooler for damage or leaks.
Coolant Change
Provides a detailed procedure for draining and refilling the cooling system with the specified coolant mixture.
Brake Light Switches Check
Guides on checking the operation of front and rear brake light switches.
Rear Brake Light Switch Adjustment
Explains how to adjust the rear brake light switch timing for proper activation.
Cable Check and Lubrication
Covers inspection of inner and outer cables for damage and lubrication procedures.
Throttle Cable Free Play Adjustment
Details how to adjust throttle cable free play on the handlebar and engine sides.
Switches, Lights, and Signals Check
Instructs on checking the operation of all switches, lights, and signals on the vehicle.
Battery Check and Charging
Covers procedures for checking battery condition and proper charging methods for VRLA batteries.
Fuse Checks
Explains how to check and replace fuses, with warnings about using correct amperage ratings.
Headlight Bulb Replacement
Provides instructions for replacing headlight bulbs, including precautions for hot bulbs and handling glass parts.
Headlight Beam Adjustment
Details how to adjust headlight beams vertically and horizontally for proper illumination.
Chassis
General Chassis Operations
Details the removal of the seat and battery, including torque specifications for related bolts and nuts.
General Chassis Operations: Tail/Brake Light Assembly Removal
Details the removal of the tail/brake light assembly, including disconnection of couplers and torque specifications.
General Chassis Operations: Cowling Removal
Provides instructions for removing side cowlings, front cowling, and related components like rearview mirrors.
General Chassis Operations: Front Cowling Removal
Details the removal of the front cowling assembly, including meter assembly, air duct, and sensor disconnects.
Front Wheel Service
Details the removal, disassembly, checking, assembly, and balancing of the front wheel.
Rear Wheel Service
Covers removal, disassembly, checking, assembly, and static balance adjustment of the rear wheel.
Front Brake Service
Provides comprehensive information on front brake discs, pads, calipers, and master cylinder maintenance.
Rear Brake Service
Details rear brake disc, pads, caliper, and master cylinder inspection, replacement, and adjustment.
Handlebar Service
Covers removal, checking, and installation of handlebars, including levers and controls.
Front Fork Service
Provides detailed instructions for removing, disassembling, checking, and assembling front fork legs, including oil and spring adjustments.
Steering Head Service
Covers removal, checking, and installation of the steering head components, including bearings and adjustment.
Rear Shock Absorber Assembly Service
Details handling, disposal, removal, checking, and installation of the rear shock absorber assembly.
Swingarm Service
Covers removal, checking, and installation of the swingarm, including pivot shaft and bearing maintenance.
Chain Drive Service
Provides procedures for removing, checking, lubricating, and installing the drive chain and sprockets.
Engine Service
Engine Inspection Procedures
Covers general engine inspection, including measuring compression pressure and checking valve clearance.
Engine Removal Procedures
Details the removal of the engine, including exhaust pipe assembly, EXUP valve, and disconnecting leads and hoses.
Camshaft Service
Covers removal, checking, and installation of camshafts, including timing chain and tensioner procedures.
Cylinder Head Service
Details the removal, checking, and installation of the cylinder head, including warpage measurement.
Valves and Valve Springs Service
Covers removal, checking, and installation of valves, springs, guides, seats, and lifters.
Generator and Starter Clutch Service
Details removal, checking, and installation of the generator and starter clutch components.
Pickup Rotor Service
Covers removal and installation of the pickup rotor, including alignment with crankshaft marks.
Electric Starter Service
Provides instructions for checking and assembling the starter motor, including commutator and brush checks.
Clutch Service
Covers removal, checking, assembly, and installation of the clutch, including friction plates, springs, and housing.
Shift Shaft Service
Details checking and installing the shift shaft, stopper lever, and related springs and retainers.
Oil Pump Service
Covers removal, checking, and assembly of the oil pump, including relief valve and oil pipes.
Crankcase Service
Details the separation, checking, and assembly of the crankcase, including lubrication and bolt tightening sequences.
Connecting Rods and Pistons Service
Covers removal, checking, and installation of connecting rods and pistons, including ring and bearing measurements.
Crankshaft Service
Details removal, checking, and installation of the crankshaft, including journal bearings and oil clearances.
Transmission Service
Covers removal, checking, assembly, and installation of the transmission, shift drum, and shift forks.
Cooling System Service
Radiator Service Procedures
Details radiator removal, checking fins, hoses, pipes, fan motor, and cap pressure.
Oil Cooler Service Procedures
Covers removal, checking, and installation of the oil cooler, including O-rings and union bolts.
Thermostat Service Procedures
Provides instructions for checking thermostat operation by testing opening temperature and installing it correctly.
Water Pump Service Procedures
Covers water pump removal, disassembly, checking components, assembly, and installation.
Fuel System
Fuel Tank and Fuel Pump Service
Details fuel tank and fuel pump removal, checking pump body and operation, and installation.
Air Filter Case and Secondary Injectors Service
Covers removal, checking, and installation of the air filter case and secondary injectors.
Air Filter Case Service: Fuel Hose Removal
Details the removal of fuel hoses from the injector rail sides, with precautions for residual fuel pressure.
Air Filter Case Service: Removal
Provides instructions for removing the upper air filter case, with tips on loosening bolts in sequence.
Throttle Body Service
Provides comprehensive procedures for checking throttle body joints, injectors, throttle bodies, and fuel pressure.
Air Induction System Checks
Covers checking the air induction system, including hoses, air cut-off valve, reed valves, and solenoid.
Air Induction System Service: Air Cut-off Valve Removal
Details the removal of the air cut-off valve, solenoid coupler, and related air induction system hoses.
Air Induction System Service: Reed Valve Removal
Covers the removal of reed valve covers, assemblies, and plates, with torque specifications.
Electrical System
Ignition System Diagnostics
Presents the ignition system circuit diagram and troubleshooting guide for no or intermittent spark issues.
Ignition System: Sidestand Operation
Explains how the sidestand and neutral switches affect engine operation and spark production.
Ignition System Troubleshooting
Provides a troubleshooting guide for ignition system failures, checking fuses, battery, coils, sensors, and switches.
Electric Starting System Diagnostics
Presents the electric starting system circuit diagram and troubleshooting steps for starter motor failures.
Electric Starting System: Cut-off Operation
Explains the operation of the starting circuit cut-off system, detailing conditions for starter motor engagement.
Electric Starting System Troubleshooting
Provides a troubleshooting guide for starter motor failures, checking fuses, battery, relays, switches, and wiring.
Charging System Diagnostics
Presents the charging system circuit diagram and troubleshooting steps for battery charging issues.
Charging System Troubleshooting
Provides a troubleshooting guide for battery charging problems, checking fuses, battery, stator coil, and rectifier/regulator.
Lighting System Diagnostics
Presents the lighting system circuit diagram and troubleshooting for failures in lights, indicators, and meter.
Lighting System Troubleshooting
Provides troubleshooting steps for various lighting failures, including bulbs, fuses, battery, switches, and relays.
Signaling System Diagnostics
Presents the signaling system circuit diagram and troubleshooting for turn signals, brake lights, horn, and speedometer.
Signaling System Troubleshooting
Provides troubleshooting steps for signaling system issues, including fuses, battery, switches, relays, and wiring.
Cooling System Diagnostics
Presents the cooling system circuit diagram and troubleshooting steps for radiator fan motor failures.
Cooling System Troubleshooting
Provides troubleshooting steps for cooling system issues, checking fuses, battery, main switch, radiator fans, coolant temperature, and wiring.
Fuel Injection System Diagnostics
Presents the fuel injection system circuit diagram, ECU self-diagnostics, and troubleshooting for various fault codes.
Fuel Injection System: ECU Self-Diagnostics
Explains the ECU's self-diagnostic function, engine trouble light indication, and fault code storage.
Fuel Injection System: Troubleshooting Method
Details troubleshooting steps for abnormal engine operation with the engine trouble warning light on, including fault code checks.
Fuel Injection System: Fault Codes 13 & 14
Covers troubleshooting for Intake Air Pressure Sensor issues: open/short circuit and hose system malfunction.
Fuel Injection System: Fault Code 15
Details troubleshooting for Throttle Position Sensor (throttle valves) open/short circuit and installation condition.
Fuel Injection System: Fault Code 17
Covers troubleshooting for EXUP servo motor circuit open/short circuit and defective servo motor or valve.
Fuel Injection System: Fault Code 18
Details troubleshooting for EXUP servo motor stuck condition, including connections and defective components.
Fuel Injection System: Fault Code 19
Covers troubleshooting for Sidestand switch open circuit, including connections and defective switch.
Fuel Injection System: Fault Codes 20 & 21
Covers troubleshooting for Intake/Atmospheric Pressure Sensor and Coolant Temperature Sensor issues.
Fuel Injection System: Fault Code 22
Details troubleshooting for Intake air temperature sensor open/short circuit, including connections and defective sensor.
Fuel Injection System: Fault Code 23
Covers troubleshooting for Atmospheric pressure sensor open/short circuit, including connections and defective sensor.
Fuel Injection System: Fault Code 24
Details troubleshooting for O2 sensor issues: no normal signals, connections, open/short circuit, and defective sensor.
Fuel Injection System: Fault Code 30
Covers troubleshooting for Lean angle sensor issues: detection, installed state, and defective sensor.
Fuel Injection System: Fault Code 33
Details troubleshooting for Cylinder-#1 ignition coil open/short circuit, including connections and defective coil.
Fuel Injection System: Fault Code 34
Covers troubleshooting for Cylinder-#2 ignition coil open/short circuit, including connections and defective coil.
Fuel Injection System: Fault Code 35
Details troubleshooting for Cylinder-#3 ignition coil open/short circuit, including connections and defective coil.
Fuel Injection System: Fault Code 36
Covers troubleshooting for Cylinder-#4 ignition coil open/short circuit, including connections and defective coil.
Fuel Injection System: Fault Code 39
Details troubleshooting for Primary injector open circuit, including connections and defective injector.
Fuel Injection System: Fault Code 40
Covers troubleshooting for Secondary injector open circuit, including connections and defective injector.
Fuel Injection System: Fault Code 41
Details troubleshooting for Lean angle sensor open/short circuit, including connections and defective sensor.
Fuel Injection System: Fault Code 42
Covers troubleshooting for Speed sensor and Neutral switch issues: no signals or open circuit.
Fuel Injection System: Fault Codes 43 & 44
Covers troubleshooting for Fuel system voltage and EEPROM errors detected by the ECU.
Fuel Injection System: Fault Code 46
Details troubleshooting for Vehicle system power supply issues and ECU internal malfunction.
Fuel Injection System: Fault Code 50
Covers troubleshooting for ECU internal malfunction: ECU memory is faulty.
Fuel Injection System: Fault Code 59
Details troubleshooting for Throttle position sensor (throttle cable pulley) open/short circuit and loose connections.
Fuel Injection System: Fault Code 60
Covers troubleshooting for Throttle servo motor open/short circuit, defective motor, or ECU internal malfunction.
Fuel Injection System: Fault Code Er-1
Covers troubleshooting for ECU internal malfunction (output signal error) related to meter communication.
Fuel Injection System: Fault Code Er-2
Details troubleshooting for ECU internal malfunction (output signal error) related to meter communication within a specified duration.
Fuel Injection System: Fault Code Er-3
Covers troubleshooting for ECU internal malfunction (output signal error) where ECU data cannot be received correctly.
Fuel Injection System: Fault Code Er-4
Details troubleshooting for ECU internal malfunction (input signal error) where non-registered data is received from the meter.
Troubleshooting
General Information for Troubleshooting
Provides a guide to basic troubleshooting, covering possible causes for starting failures and engine performance issues.
Starting Failures: Engine Issues
Lists potential causes for starting failures related to cylinder, piston, air filter, and crankcase components.
Starting Failures: Fuel System Issues
Identifies potential causes for starting failures related to fuel tank, fuel pump, and throttle body issues.
Starting Failures: Electrical System Issues
Lists potential causes for starting failures related to battery, fuses, spark plugs, ignition coils, ECU, switches, and starting system components.
Incorrect Engine Idling Speed
Details potential causes for incorrect engine idling speed related to cylinder head, air filter, and throttle body.
Poor Medium and High Speed Performance
Lists potential causes for poor performance at medium and high speeds, including air filter and YCC-T/YCC-I system issues.
Faulty Gear Shifting
Covers potential causes for difficult gear shifting, referring to clutch drag issues.
Shift Pedal Does Not Move
Lists potential causes for a non-moving shift pedal, including shift shaft and drum issues.
Jumps Out of Gear
Identifies potential causes for the transmission jumping out of gear, related to shift shaft, forks, drum, and transmission.
Faulty Clutch
Covers potential causes for clutch slips or drags, including assembly, adjustment, and oil issues.
Overheating: Engine Issues
Lists potential causes for engine overheating related to coolant passages and carbon buildup.
Overcooling
Details potential causes for overcooling, primarily related to a thermostat stuck open.
Poor Braking Performance
Lists potential causes for poor braking performance, including worn pads, discs, fluid leaks, and caliper issues.
Faulty Front Fork Legs
Covers causes for front fork leg issues, including leaking oil, bent tubes, damaged springs, and incorrect oil level.
Unstable Handling
Lists potential causes for unstable handling, related to handlebars, steering head, front forks, and swingarm.
Faulty Lighting or Signaling System
Covers causes for failures in lighting and signaling systems, including bulbs, fuses, battery, switches, and wiring.
Self-Diagnostic Function and Diagnostic Code Table
Self-Diagnostic Function Table
Lists fault codes, corresponding items, and refers to troubleshooting methods for system malfunctions.
Communication Error with the Meter
Provides details on fault codes related to communication errors between the ECU and the meter.
Diagnostic Code: Sensor Operation Table
Lists diagnostic codes for sensor operations, including expected meter display values and procedures.
Diagnostic Code: Actuator Operation Table
Details diagnostic codes for actuator operations, including expected actuation and procedure for checks.
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